High-power ultrasonic horn

Abstract

An ultrasonic horn for use in a chemical reactor is formed as a unitary piece of material whose length is approximately equal to the wavelength of ultrasonic waves through the material at a selected ultrasonic frequency. The horn has a conically shaped distal end and a mounting surface at its proximal end, plus a mounting fixture between the proximal and distal ends for mounting the horn to a flow-through reactor with the distal end protruding into the reactor interior while the proximal end extends outside the reactor. The horn further contains a seal between the proximal and distal ends to seal the horn to the interior of a reaction vessel in a fluid-tight manner. With the unitary construction and the conical distal end, the horn is capable of transmitting high power ultrasonic waves to the reactor interior without damage to the horn or its mounting fixtures.

1 . An ultrasonic horn comprising 
 a solid elongate body having a longitudinal axis, one end of said longitudinal axis defined as a proximal end and the other as a distal end,    said elongate body being a unitary piece of material capable of ultrasonic vibration, the length of said elongate body being approximately equal to the wavelength of ultrasonic waves through said material at a selected ultrasonic frequency,    said elongate body being conically shaped at said distal end, and having a mounting surface at said proximal end for an ultrasound transducer and a mounting fixture between said proximal and distal ends for mounting said elongate body to a flow-through reactor such that said distal end extends into the interior of said flow-through reactor.    
   
   
       2 . The ultrasonic horn of  claim 1  wherein said material is an alloy tool steel.  
   
   
       3 . The ultrasonic horn of  claim 1  wherein said material is an alloy tool steel containing at least about 4% chromium.  
   
   
       4 . The ultrasonic horn of  claim 1  wherein said material is steel and said length is from about 20 cm to about 50 cm.  
   
   
       5 . The ultrasonic horn of  claim 1  wherein said material is an alloy tool steel containing at least about 4% chromium and said length is from about 20 cm to about 50 cm.  
   
   
       6 . The ultrasonic horn of  claim 1  wherein said elongate body has a profile comprising a tapering section between said proximal end and said distal end.  
   
   
       7 . The ultrasonic horn of  claim 1  further comprising sealing means between said mounting flange and said distal end for sealing said horn against an interior wall surface of a reactor.  
   
   
       8 . A continuous flow-through reactor comprising: 
 a reaction vessel having a longitudinal axis and inlet and outlet ports, said inlet port arranged to direct an inflowing reaction mixture along said longitudinal axis, and    an ultrasonic horn comprising a solid elongate body having a longitudinal axis, one end of said longitudinal axis defined as a proximal end and the other as a distal end, said elongate body being a unitary piece of material capable of ultrasonic vibration, the length of said elongate body being approximately equal to the wavelength of ultrasonic waves through said material at a selected ultrasonic frequency, said elongate body being conically shaped at said distal end, and having a mounting surface at said proximal end for an ultrasound transducer and a mounting fixture between said proximal and distal ends for mounting said elongate body to said reaction vessel such that said distal end extends into the interior of said reaction vessel.    
   
   
       9 . The continuous-flow reactor of  claim 8  wherein said horn material is an alloy tool steel.  
   
   
       10 . The continuous-flow reactor of  claim 8  wherein said horn material is an alloy tool steel containing at least about 4% chromium.  
   
   
       11 . The continuous-flow reactor of  claim 8  wherein said horn material is steel and said length is from about 20 cm to about 50 cm.  
   
   
       12 . The continuous-flow reactor of  claim 8  wherein said horn material is an alloy tool steel containing at least about 4% chromium and said length is from about 20 cm to about 50 cm.